superrange Super Series 4, Super Plus High efficiency modular boilers 50-600kW Commercial & Industrial Boilers
the super range Contents Introduction 3 The Super range 4-5 Product specification 6-7 System requirements 8-11 General & dimensional data - Super Series 4 12-17 General & dimensional data - Super Plus 18-19 2
Introduction Ideal Boilers Super range is the most successful modular boiler system on the market. Proven to deliver exceptional high efficiency commercial and industrial heating performance. The Super range consists of the Super Series 4 comprising identical 50kW modules with outputs from 50kW to 600kW and the Super Plus comprising of 100kW modules with outputs from 200kW to 600kW. Heat exchangers are sited in a combined casing/combustion chamber assembly, effectively creating semi-condensing conditions within each module. This design achieves efficiencies of up to 85% gross cv (94% nett cv) at both full and part load conditions. Because of its modular design, Super range eliminates oversizing problems to offer optimum operating efficiency. Maximum system load determines the appropriate number of modules for a given installation - from 50kW (170,600 Btu/h) up to 600kW (2,047,200 Btu/h). Sequence controlled operation automatically matches the number of modules firing to requirements, so reducing fuel consumption. Ideal for simple vertical or horizontal assembly, Super range installation can save over 30% of the typical plantroom space normally used by conventional boilers. And the system incorporates a range of design innovations reducing boiler installation and servicing time. Super efficient, straightforward to specify, easy to install and service. Ideal s Super range is the proven performer in high efficiency modular boiler systems. Conforms with all relevant European standards and requirements 3
the super range Super Series 4 50-600kW The Super Series 4 control panel 50kW modules Vertical and horizontal models High efficiency 85% gross cv (94% nett cv) Low NOx emissions (class 5) Low noise Compact size Sequence controlled Easy to install and service Complete package - incorporating single flue outlet, gas and water headers included 4 Remote indication contacts
Super Plus 200-600kW The Super Plus control panel The Super Plus 200/S 100kW modules Horizontal assembly High efficiency 85% gross cv (94% nett cv) Low NOx emissions (class 5) Heat Exchange Module Figure 1 Low noise Ultra compact Sequence controlled Easy to install and service Complete package - incorporating single flue outlet, gas and water headers included Optional remote indication kits 5
product specification Performance Heat output from each boiler module is 50kW (Super Series 4) and 100kW (Super Plus) with the number of modules in use dependent on the maximum load. Fitted on slide rails, the modules are located in an insulated stainless steel boiler casing. The products of combustion first give up their heat to water flowing through the modules then are discharged. Water flows continuously through all the modules on the reverse return principle. It enters the return header on the left hand side of the boiler and then flows through the modules to the flow header on the right hand side. As the load is satisfied the upper module switches off first, then the middle, and lastly the lower module. Water flowing through the upper modules is kept warm by exhaust gas from lower modules which are firing. There is only a minimal loss of efficiency as modules shut down. Modules are connected in parallel across the two headers via flexible hose connections on boilers of 200kW output and above. The Super range complies with the new Building Regulations 2000 - Conservation of Fuel & Power (Part L). Approved efficiency is approx 94% net (85% gross) full load, at part load high efficiencies are maintained at virtually full load levels. Boiler Range Certificate No. Notified Body Reference Super Series 4 50-600kW models BE-87/97/3/MI Advantica 0087 Super Plus 200-600kW models Technologies Ltd 0087 Construction The stainless steel boiler casing is externally insulated with stucco finish, aluminium-faced insulation. Module covers are stove-enamelled orange. Super Series 4 - The heat exchanger consists of extruded copper finned tubes in a circular arrangement around the gas burner. Copper tubes are expanded into cast iron headers, onto which cast iron cover plates are bolted. Super Plus - The heat exchanger is constructed in the same manner but in aluminium alloy. The front cover plate is cast iron with similar flow and return elbows. The mating surfaces are ground and a seal is made with gaskets. Each module is pressure tested to 11 bars (160 lb/in 2 ). The module water inlet and outlet castings are 1 1 2 nominal bore and are connected to the flow and return headers with standard flanges to BS 4504. The buoyancy of hot gases from the gas burner is overcome by using a slotted aluminium distribution screen arranged around the outside of the finned tubes. The slots have sufficient resistance to ensure even gas flows over the finned tubes. Burner The burner is a perforated stainless steel cylinder producing a perfectly symmetrical gas flame. Gas and air in the correct proportions are pre-mixed in the burner fan which blows the gas/air mixture into the inside of the burner. A mixture distribution cone ensures even flow through holes in the cylindrical burner. Hot products of combustion flow radially outwards around the finned tubes, giving up their heat to the water flowing through the tubes. Exhaust gases are then discharged into the boiler casing. Ignition and burner performance can be observed through the sight glass mounted on the front plate. Options Boiler Water flow switch for boiler protection in the event of pump failure External sequence control kit Remote indication of boiler on, lockout and overheat for each module Module blanking off pack Super Series 4 Super Plus Gas Controls Each module has the following items in the gas supply train: - Module gas cock on gas header branch - Twin a.c. solenoid valve - Gas air control unit - Gas injector The positive and negative pressure lines from the fan act on the diaphragm of the gas/air control unit (Super Plus: gas pressure switch). This allows gas to pass to the burner in proportion to the amount of air delivered by the fan, thereby accommodating variations in flue draught. A closed flue will allow no gas to pass. The minimum dynamic gas supply pressure required at the inlet to the boiler is 15 mbar (6 in. w.g.) with all modules firing. Maximum gas supply pressure is 25 mbar (10 in. w.g.). 6
Electrical Controls Each module has its own independent complete control system incorporating: Packing Boilers are supplied in the following packs:- Boiler Super Series 4 / Super Plus Boiler Super Series 4 / Super Plus Boiler casing 2 x 2 PCB with separate spark generator Water headers Ignition electrode Gas header Ionisation probe Adjustable water temperature electronic control thermostat Non-adjustable limit thermostat with manual reset Modules A full site assembly and commissioning service is available at an extra charge. On/off switch LEDs to provide visual indication of mains on, burner on, Ignition lockout and overheat lockout Module electrical plug To achieve correct matching of boiler output and variations in load, modules switch in sequence automatically. The electronic control thermostat senses return water temperature to each module and makes simple adjustments quickly and accurately. The electronic control arrangements also provide step-start ignition of modules on initial light-up. System Application The Super range is designed for central heating of commercial/industrial premises and also for supplying domestic hot water via a calorifier or plate heat exchanger. It is suitable for open vented and pressurised systems and can be connected to fully pumped, open vented or pressurised central heating, indirect domestic hot water and combined systems. Note: The Super range is not suitable for direct hot water supply or gravity heating/hot water systems. Maximum static head 61 metres (200 feet) Quality Maximum working pressure 6 bar (87psi) As with all Ideal boilers, the Super range is engineered to the highest quality standards. Ideal boiler products meet or exceed the requirements of all relevant standards. Before despatch each module is fired and the control system, fan and burner are fully tested. The control valve is also adjusted to give the correct gas flow rate. Ideal Boilers are recognised as a world class manufacturer. assurance of quality Maximum design flow temperature 82 C (180 F) Operation Super Series 4 In certain conditions the normal mode of boiler operation is preceded by a period in which the complete boiler casing is given a three volume air change. In the case of a single 50kW boiler with no wiring centre, only its own 5 second nominal pre-purge period occurs. When the module electronic thermostat calls for heat the fan switches on and purges the combustion chamber for 15 seconds. Then the ignition spark is generated from the ignition electrode to the burner and the gas valves are opened. Super Plus When the electronic thermostat calls for heat and no modules are firing, all fans will purge the casing for 70 seconds. The fan from the first module called upon will then purge its own combustion chamber for an additional 35 seconds and each subsequent module likewise prior to the start of the ignition sequence. Then the ignition spark is generated from the ignition electrode to the burner and the gas valves are opened. Gas is delivered through the injector to the distribution plate at the inlet to the fan. This pre-mixes the gas with the air. It then passes from the fan through a multi-hole plate to the burner, where it is ignited. The flame is sensed via the ionisation probe and the PCB control. The valves remain open until the thermostat is satisfied. low NOx (Class 5) performance for life The module is protected against blockage of the burner, heat exchanger, or flue and against fan failure by the compensating valve set. This senses the differences in pressure across the multi-hole plate and controls the gas injector pressure according to the amount of air flow. After combustion, the products flow past the finned tubes and through the gas distribution screen into the boiler casing, so giving up heat to the water flowing through the tubes. BS EN ISO 9001: 2000 7
system requirements Installation For safety, a competent CORGI (Council for the Registration of Gas Installers) registered installer must fit this appliance. CORGI requires its members to work to satisfactory standards. Boiler installation should comply with relevant British Standard Specifications, Codes of Practice, and current Building Regulations, together with any special regional requirements of the Local Authorities, Gas Supplier, and Insurance Company, and in particular: BS 6891: Low pressure installation pipes, BS 6644: Installation of Gas Fired Boilers, BS 6880: Part 1-3 Central Heating by low pressure hot water, CP 342.2 Centralised hot water supply, British Gas publications IM/II Flues for commercial and industrial gas fired boilers and air heaters. All electrical wiring must comply with IEE Regulations for the electrical requirement of buildings. Manufacturer s notes must not be taken as overriding statutory obligations. vertical or horizontal models, easy to install Minimum clearances from walls or other fixed objects to allow for installation, maintenance, and the free access of combustion air are shown in the boiler clearance diagram. The Super range is easy to install. Even the largest boiler in the range will go through a standard doorway. If the water headers and the modules are removed from the boiler casing, then one man can easily handle up to the 100kW unit, and two men up to the largest size. Assembly on site does not require any special tools. Because of the very high efficiency of the Super range precautions must be taken to provide condensate drains at the lowest bend in the flue system. A drainpipe, suitable for connection to 22mm pipe, is located at the bottom of the boiler casing. Condensation will occur only on warming up, when the return water temperature is below 55 C (131 F) - the dew point of water. To ensure efficient and reliable boiler operation: - The constant water flow through the boiler, within 10% of that indicated in the data table, must be maintained at all times when any of the modules are operating. At these flow rates, the hydraulic resistance is Super Series 4 125mbar (50 in. w.g.) or Super Plus 98mbar (39 in. w.g.) plus or minus 20% irrespective of boiler size. - Protection against circulating pump failure must be provided. - The chimney system must be CLASS 1 specification and be lined and insulated with the equivalent of 50mm (2in) of mineral wool. A drainage point must be provided. - The chimney draught must be controlled between neutral and 0.2mbar (0.08 in. w.g.). - Boiler house cleanliness is important and concrete floors should be sealed to keep dust levels down to a minimum. - Regular maintenance by competent personnel is essential to the safe and reliable operation of the boiler. Full details of these requirements are given in the Installation and Servicing Instruction books available on request from Ideal Boilers. Water Treatment The Super Plus boiler has an aluminium alloy heat exchanger. The ONLY water treatments Ideal Boilers have approved are Fernox Copal and Betz Dearborn Sentinel X100 (current suitability should be confirmed with the manufacturer). ANY OTHER treatment will render the guarantee of Ideal Boilers for this product INVALID. The above is not applicable to the Super Series 4. Water contained in all heating and indirect hot water systems, particularly open vented systems, requires basic treatment. It is wrong to assume that because boilers are operating in conjunction with what is an apparently closed circuit, an open vented system will not under normal circumstances allow damage or loss of efficiency owing to hardness salts and corrosion once the initial charge of water has been heated several times. One millimetre of lime reduces the heat conversion from flame via metal to water by 10%. In practice the accumulation of these salts is liable to cause noises from the boiler body or even premature boiler failure. Corrosion and the formation of black iron oxide sludge will ultimately result in premature radiator failure. Open vented systems are not completely sealed off from the atmosphere, because it is necessary to provide a tank open to atmosphere if proper venting and expansion of system water is to be achieved. The same tank is used to fill the system with water and it is through the cold feed pipe that system water expands into the tank when the boiler passes heat into the system. Conversely, when the system cools, water previously expanded is drawn back from the tank into the system together with a quantity of dissolved oxygen. Even if leakage from the heating and hot water system is eliminated there will be evaporation losses from the surface of the tank. Depending on ambient temperature these may be high enough to evaporate a large portion of the system water capacity over a full heating season. Corrosion will always occur within a heating/hot water system to a greater or lesser degree irrespective of water characteristics, unless the initial fill water from the mains is treated. Even the water in closed systems will promote corrosion unless treated. 8
Water Treatment continued For these reasons, Ideal Boilers strongly recommends that when necessary the system be thoroughly cleaned prior to the use of a stable inhibitor which does not require continual topping up to combat the effects of hardness, salts, and corrosion on the heat exchanger and its associated systems. The company advises direct contact with major water treatment specialists such as Betz Dearborn Ltd, Sentinel Division, Widnes, Cheshire, WA8 8UD Telephone: 0151 424 5351 or Fernox, Fry Technology UK, Tandem House, Marlowe Way, Beddington Farm Road, Croydon CRO 4XS Telephone: 0870 601 5000. Flue Systems Depending on particular site conditions the flue size required may be as much as two sizes smaller than that required for a conventional atmospheric gas boiler of similar output. The fitting of a draught stabiliser will be necessary on all individual boilers. In certain circumstances it may be possible to use a chimney sized smaller than the flue connection provided on the boiler. single flue outlet Ventilation Detailed recommendations for air supply are quoted in BS 6644. The following notes are for general guidance and the standard should be consulted for full information. Natural Ventilation Permanent openings at low and high level communicating directly with the outside air must be provided. The total minimum free area of the openings must be as follows: Low level (inlet) - 540 cm 2 plus 4.5 cm 2 per kw in excess of 60kW total rated input (gross). High level (outlet) - 270 cm 2 plus 2.25 cm 2 per kw in excess of 60kW total rated input (gross). Mechanical Ventilation Air can be supplied: (a) By a fan connected to a low level opening and discharged naturally via one or more high level openings. (b)by a fan connected to a low level opening and discharged by means of a second fan at a high level opening. Existing brick chimneys can be used provided they are lined, insulated and drained. Super range boilers are suitable for fan diluted or induced draught fan flue systems. The following sizes of boiler are supplied with one or more blanking plates fitted: Super Series 4 - alternative 150-250 vertical and horizontal - 350 vertical - 450 to 550 vertical and horizontal models Super Plus - 300/3 (3 in 400 casing) - 300/3 alternative (3 in 600 casing) - 400/4 alternative (4 in 600 casing) - 500/5 (5 in 600 casing) The output of these boilers can be increased by the removal of blank plates and the fitting of additional modules provided that the flue system is sized for the higher output on initial installation. Note: Any fan installed for extraction purposes must not cause a negative pressure (relative to the outside atmosphere) to develop in the boiler house as this will affect burner performance. The air flow rates for forced draught boilers are calculated from the formula. Inlet air - 0.9m 3 /sec per 1000kW of heat input. Extract air - 0.6m 3 /sec per 1000kW of heat input. All air inlet and extract fans must be fitted with automatic controls causing safety shutdown or lockout of the boiler(s) in the event of inlet or extract air flow failing. 9
system requirements System Design The Super range is suitable for connection to all types of fully pumped systems provided that the constant water flow through the boiler is not affected by manual or automatic operation of controls within the system. Protection against pump failure must be provided, eg; by the fitting of a water flow switch. A suitable switch can be obtained from Ideal Boilers. The modular arrangement of the boiler and its high tolerance to condensation allows for efficient control of heat output without the use of mixing valves. Operation should be at constant volume flow rate with 11 C (20 F) temperature difference across boiler and system. General guidance on system layouts are shown in the diagrams below (see Figures 2, 3 and 4). Figure 2: Simple combined heating and DHW System } 1. Cold feed Sizes MUST comply 2. Open vent with BS 6644 3. Safety valve 4. Water flow switch 5. Dual primary pumps 6. Mixing header 7. Feed and expansion tank Figure 2 is intended as a guide ONLY with the following assumptions and conditions applying: - Open vent and cold feed connections are made to the boiler flow and return manifolds respectively. - The pump is positioned on the flow. The water velocity is assumed to be below 1.5m/s (5ft/s) and the volume flow rate to be 1.07 l/s (14.1 gal/m - Super Series 4) or 2.15 l/s (28.4 gal/m - Super Plus) per boiler module. - In an existing system a filter/strainer should be positioned into the common return pipework to prevent debris entering the heat exchangers. Note: - Single module boiler requirements are as for multi-module boilers. - Hydraulic resistance for all Super Series 4 boilers is 125 mbar (50 in.w.g.) or Super Plus boilers is 98 mbar (39 in.w.g.) at the design flow rate. - Minimum tank height dimensions shown may have to be increased to comply with pump manufacturer s requirements to avoid cavitation. It may also be necessary to consider the requirements of Guidance Note: PM5, issued by the Health & Safety Executive. Refer also to the Installation Instructions. - Mixing headers should be sized at 1 standard pipe size larger than the common flow and return pipework. * Super Series 4: 2000mm (79 in.), Super Plus: 1600mm (63 in.). 10
System Design Figure 3: Example of multi-zone heating and DHW system connected to multi-module boiler 1. Cold feed 2. Open vent 3. Safety valve 4. Water flow switch 5. Dual primary pumps 6. Mixing header 7. Feed / expansion cistern 8. Compensator C - Cylinder thermostat controls pump E - Air temperature sensors T - Timers Note: Super Series 4 The primary pump duty is 1.07 l/s x 4 modules and 4.28 l/s (56.6 gal/m) against 125 mbar (50 in. w.g) plus pipework resistance. Super Plus The primary pump duty is 2.15 l/s x 4 modules and 8.6 l/s (113.8 gal/m) against 98 mbar (39 in. w.g) plus pipework resistance. Figure 4: Example of multi-zone heating and DHW system connected to two multi-module boilers Example 1 Example 2 Open vents, cold feet and safety valves OMITTED for clarity Figure 4: example 1 shows an application with independent boiler primary pumps based on 11 C (20 F) temperature difference across boiler. Boiler primary pumps (dual sets) are rated at 4.28 I/s (56.4 gal/m) against 125 mbar (50 in.w.g - Super Series 4) or 8.6 I/s (113.8 gal/m) against 98 mbar (39 in.w.g - Super Plus) plus pipework resistance. Example 2 shows an application with common boiler primary pump based on an 11 C (20 F) temperature difference across the boiler. Boiler primary pump (dual set) is rated at 8.56 l/s (112.8 gal/m) against 125 mbar (50 in.w.g - Super Series 4) or 17.2 I/s (227.6 gal/m) against 98 mbar (39 in.w.g - Super Plus) plus pipework resistance. Note: In both cases modules should be switched on each boiler simultaneously to give a variety of turndown ratios. Boiler primary pumps must run at all times, irrespective of the number of modules firing on either boiler. 11
general data General Data - Super Series 4 (50V - 300H) Model 50V 100V 150V 200V 250V 300V 150VA 250H 300H No. of modules 1 2 3 4 5 6 3 5 6 Boiler input Boiler output Gas rate kw 58.8 117.6 176.4 235.2 294.0 352.8 176.9 294.0 352.8 Btu/h 200.6 401.3 601.9 802.5 1003.1 1203.8 601.9 1003.1 1203.8 kw 50 100 150 200 250 300 150 250 300 Btu/h 170.6 341.2 511.8 682.4 853.0 1023.6 511.8 853.0 1023.6 m 3 /h 5.5 11.0 16.5 22.1 27.6 33.1 16.5 27.6 33.1 ft 3 /h 195 389 584 779 973 1168 584 973 1168 9.0% CO 2 m 3 /s 0.027 0.055 0.082 0.110 0.137 0.164 0.082 0.137 0.164 Approx flue gas volume 120 C at 120 C (248 F) 9.0% CO 2 ft 3 /m 58 116 174 232 290 384 174 290 348 248 F Hydraulic resistance kn/m 2 12.5 in.w.g. 50 Power consumption watts 150 300 450 600 750 900 450 750 900 Flow tappings & Return tappings mm 40 50 65 65 80 80 65 80 80 in 1 1 2 2 2 1 2 2 1 2 3 3 2 1 2 3 3 Maximum static water head m 61 ft 200 Required water flow rate +/-10% l/s 1.07 2.14 3.21 4.28 5.35 6.42 3.21 5.35 6.42 gal/m 14.1 28.2 42.3 56.4 70.5 84.6 42.3 70.5 84.6 Gas inlet connection Rc 3 4 1 1 1 4 1 1 4 1 1 2 1 1 2 1 1 4 1 1 2 1 1 2 in. BSP 3 4 1 1 1 4 1 1 4 1 1 2 1 1 2 1 1 4 1 1 2 1 1 2 Min. dynamic gas pressure required mbar (gauge) 15.0 at the boiler inlet for the rated input in.w.g. 6.0 Electricity supply 230V ~ 50Hz single phase Nominal flue size (to BS 835) mm 125 175 200 250 250 300 200 250 300 in 5 7 8 10 10 12 8 10 12 Diverter outlet socket mm 159 213 238 288 288 339 238 288 339 internal diameter in 6 1 4 8 3 8 9 3 8 11 3 8 11 3 8 13 3 8 9 3 8 11 3 8 13 3 8 Weight modules Weight casing / insulation Weight gas / water headers Water content kg 53 106 159 212 265 318 159 212 318 lb 116 232 348 464 580 696 348 580 696 kg 29.1 47.7 61.5 76.6 106.6 98.9 84.0 107.0 99.0 lb 64.1 105.2 135.5 168.8 235.0 218.0 185.0 235.0 218.0 kg - 34 53.6 59.4 89.4 94.3 53.4 92.2 96.7 lb - 75 118 131 197 208 118 203 213 l 4.5 11.9 20.7 26.2 37.7 44.5 21.7 39.7 44.5 gal 1.0 2.6 4.6 5.9 8.3 9.9 4.9 8.8 9.9 Note: To obtain gas consumption in l/s, divide gross heat input (kw) by a calorific value of 37.8 (MJ/m 3 ). Note: Flange sizes to BS 4504: Part 1: Table 16. 12
General Data - Super Series 4 (350V - 600H) Model 350V 400V 450V 500V 550V 600V 450H 500H 500H 600H No. of modules 7 8 9 10 11 12 9 10 11 12 No. of blanking plates 1-3 2 1-3 2 1 - Boiler input Boiler output Gas rate 9.0% CO2 Approx flue gas volume 120 C at 120 C (248 F) 9.0% CO2 248 F Hydraulic resistance kw 411.6 470.4 529.2 583 646.8 705.6 529.2 583 646.8 705.6 Btu/h 1404 1605 1805 2006 2207 2407 1805 2006 2207 2407 kw 350 400 450 500 550 600 450 500 550 600 Btu/h 1194 1365 1535 1706 1877 2047 1535 1706 1877 2047 m 3 /h 38.6 44.1 49.7 55.2 60.7 66.2 49.7 55.2 60.2 60.7 ft 3 /h 1363 1557 1752 1947 2143 2336 1752 1947 2143 2336 m 3 /s 0.191 0.219 0.246 0.273 0.301 0.328 0.246 0.273 0.301 0.328 ft3/m 406 464 522 580 638 696 522 580 638 696 kn/m 2 12.5 in.w.g. 50 Power consumption watts 1050 1200 1350 1500 1650 1800 1350 1500 1650 1800 Flow tappings & Return tappings mm 100 100 125 125 125 125 125 125 125 125 in 4.0 4.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 Maximum static water head m 61 ft 200 Required water flow rate +/-10% l/s 7.49 8.5 9.63 10.70 11.77 12.84 9.63 10.70 11.77 12.84 gal/m 98.7 112.8 126.9 141.0 155.1 169.2 126.9 141.0 155.1 169.2 Gas inlet connection Rc 2 in. BSP 2 Min. dynamic gas pressure required mbar (gauge) 15.0 at the boiler inlet for the rated input in.w.g. 6.0 Electricity supply 230V ~ 50Hz single phase Nominal flue size (to BS 835) mm 350 350 400 400 450 450 400 400 450 450 in 14 14 16 16 18 18 16 16 18 18 Diverter outlet socket mm 400 400 450 450 501 501 450 450 501 501 internal diameter in 15 3 4 15 3 4 17 1 4 17 1 4 19 3 4 19 3 4 17 1 4 17 1 4 19 3 4 19 3 4 Weight modules kg 371 424 477 530 583 636 477 530 583 636 lb 818 935 1052 1168 1282 1402 1052 1168 1282 1402 Weight casing / insulation kg 134 126 197 190 182 175 197 190 182 175 lb 295 278 435 418 402 386 435 418 402 386 Weight gas / water headers kg 260 263 311 313 315 318 298 300 302 304 lb 573 580 686 690 694 701 657 661 665 670 Water content l 63.3 68.1 97.6 102.4 107.2 112 92.6 97.4 102.2 107 gal 14.1 15.1 21.6 22.7 23.9 24.9 20.5 21.6 22.7 23.7 Note: To obtain gas consumption in l/s, divide gross heat input (kw) by a calorific value of 37.8 (MJ/m 3 ). Note: Flange sizes to BS 4504: Part 1: Table 16. 13
dimensional data Boiler Dimensions - Super Series 4 (50kW - 150kW) All dimensions in millimetres fp = foot projection gc = gas connection 50kW Vertical 100kW Vertical 150kW Vertical 150kW Alternative arrangement Vertical 14
Boiler Dimensions - Super Series 4 (200kW - 300kW) All dimensions in millimetres fp = foot projection gc = gas connection rc = return connection 200kW Vertical 250 / 300kW Vertical 250 / 300kW Horizontal 15
dimensional data Boiler Dimensions - Super Series 4 (350kW - 600kW) All dimensions in millimetres gc = gas connection 350 / 400kW Vertical 450 / 600kW Vertical 450 / 600kW Horizontal 16
Boiler Clearances - Super Series 4 All dimensions in millimetres to wall or adjacent boiler Diagram applicable for 50-300kW models Diagram applicable for 350-600kW models 17
general & dimensional data General Data - Super Plus (200/S - 600/6) Model 200/S 300/3 400/4 300/3 400/4 500/5 600/6 Alternative Alternative No. of modules 2 3 4 3 4 5 6 Boiler input gross kw 235 353 471 353 471 588 706 Btu/h 802.9 1204.4 1607.0 1204.4 1607.0 2006.2 2408.8 Boiler output kw 200 300 400 300 400 500 600 Btu/h 682.4 1023.6 1364.8 1023.6 1364.8 1706.0 2047.2 Gas rate m 3 /h 22.1 33.1 44.2 33.1 44.2 55.1 66.2 ft 3 /h 778.8 1168.0 1558.7 1168.0 1558.7 1945.8 2336.4 8.5% CO2 m 3 /s 0.109 0.164 0.218 0.164 0.218 0.273 0.327 Approx flue gas volume 100 C 8.5% CO 2 ft 3 /m 231 397 463 347 463 578 694 212 F Hydraulic resistance mbar 98 in.w.g. 39 Power consumption watts 400 600 800 600 800 1000 1200 Flow tappings & Return tappings mm 65 125 125 125 125 125 125 in 2 1 2 5 5 5 5 5 5 Maximum static head m 61 ft 200 Required water flow rate +/-10% l/s 4.3 6.5 8.6 6.5 8.6 10.8 12.9 gal/m 56.8 85.2 113.6 85.2 113.6 142.0 170.4 Gas inlet connection Rc 1 1 2 2 2 2 2 2 2 in. BSP 1 1 2 2 2 2 2 2 2 Min. dynamic gas pressure required mbar (gauge) 14.6 14.8 15.1 14.8 15.1 15.5 16 at the boiler inlet for the rated input in.w.g. 5.8 5.9 6.1 5.9 6.1 6.2 6.4 Electricity supply Nominal 230V ~ 50Hz single phase Nominal flue size (to BS 835) mm 250 350 350 450 450 450 450 in 10 14 14 18 18 18 18 Diverter outlet socket mm 288 401 401 500 500 500 500 internal diameter in 11.4 15.8 15.8 19.7 19.7 19.7 19.7 Weight modules kg 138.4 207.6 276.8 207.6 276.8 346.0 415.2 lb 305.0 457.5 610.0 457.5 610.0 762.5 915.0 Weight casing / insulation kg 134 144 144 208 208 208 208 lb 295 318 318 459 459 459 459 Weight gas / water headers kg 36.1 47.6 47.6 62.4 62.4 62.4 62.4 lb 79.7 104.9 104.9 137.5 137.5 137.5 137.5 Water content l 19.8 29.7 39.6 29.7 39.6 49.5 59.4 gal 4.4 6.5 8.7 6.5 8.7 10.9 13.1 Note: To obtain gas consumption in l/s, divide gross heat input (kw) by a calorific value of 37.8 (MJ/m 3 ). Note: Flange sizes to BS 4504: Part 1: Table 16. 18
Boiler Dimensions and Clearances - Super Plus All dimensions in millimetres unless stated. Super Plus 200/S Super Plus 300/3 & 400/4 Super Plus 500/5 & 600/6 500* for 18in. Flue pipe = Super Plus 500/5 & 600/6 400 for 14in. Flue pipe = Super Plus 300/3 & 400/4 Note: Headroom must be the boiler height plus any pipework and flue requirements. 19
The Ideal Commercial Range Boiler output Atmospheric Boilers kw Btu/h (000) 20 40 100150 200 600 800 1000 1500 3500 68 136 340511 682 2047 2729 3412 5118 11942 Concord CXA/H 40-120 Concord CXS/H, CXSD/H 40-120 Concord CXSi/H, CXDi/H Concord ES/H Concord Modular 110-180 140-380 80-720 High Efficiency Boilers Concord Super Series 4 50-600 Concord Super Plus 200-600 Condensing Boilers W 45-80 Concord CXC 49-116 Plus 80-280 GT Condenser 180-990 Pressure Jet Boilers Buccaneer GTE 21-39 Falcon GTE 36-102 Harrier GTE 105-330 Viceroy GT 300-780 Viscount GTE Vanguard L 130-3500 754-1450 Hot water solutions Buccaneer / Falcon Combination Boilers 21-64 Senator Calorifiers 150-1000 litres Contact Numbers Sales Tel: 01482 498690 Fax: 01482 498621 Technical Tel: 01482 498376 Fax: 01482 498621 Approval (Natural gas) These appliances are certified by British Gas and comply with EN656 safety and performance standards for gas boilers. Ideal Boilers pursues a policy of continuous improvement in design and performance of its products and reserves the right to vary specification without notice. Statutory rights of the consumer are not affected. Assurance of quality BS EN ISO 9001: 2000 Training Tel: 01482 498432 Fax: 01482 498605 Ideal Boilers Limited, PO Box 103, National Avenue, Kingston upon Hull HU5 4JN. www.idealcommercialboilers.com email: commercial_heating@idealboilers.com HS/1/04 Issued subject to standard conditions 2004 Ideal Boilers Limited